Educating and training personnel on food safety in the dairy processing industry can appear to be a daunting task. However, the existence of industry-specific training modules and resources significantly alleviates this challenge. With the vast array of topics and details to focus on within a dairy operation, it is crucial that every employee comprehends the importance of these matters. In reality, the breadth of concepts associated with dairy food safety is so extensive that even an intensive multi-day crash course would struggle to cover all essential aspects of a processor’s operation.
The International Dairy Foods Association (IDFA) recognizes that dairy processors are currently seeking help across a wide range of subjects. According to Roberta Wagner, the IDFA’s senior vice president of regulatory and scientific affairs, trending topics include Good Manufacturing Practices (GMPs), risk assessment and hazard analysis, hygienic design, and environmental monitoring programs aimed at detecting bacteria such as Cronobacter, Salmonella, and Listeria. This list is just the tip of the iceberg.
Furthermore, processors are increasingly interested in education regarding the Food Safety Modernization Act (FSMA), supplier management programs, recall plans, root cause analysis, pasteurization processes, regulatory compliance, and sanitation practices for both dry and wet equipment. It’s important to note that the training and education needs are highly variable, depending on the size of the company and the specific roles of individuals within those organizations.
Diverse Training Approaches
In large-scale dairy operations, it is common for every employee, including those in administrative or finance roles, to complete a food safety training module. On the other hand, smaller artisan dairy producers may have vastly different training requirements and capabilities, as highlighted by Tim Stubbs, senior vice president of product research and food safety at the Innovation Center for US Dairy. He explains that larger companies may involve their staff in up to ten modules over several years, while smaller operations might need more tailored training solutions.
Training methods can be diverse, including in-person lectures, hands-on training, and video tutorials, chosen based on what is most suitable for the task. Wagner notes that dairy processors are increasingly adopting digital tools and technology to facilitate training. The pandemic accelerated the shift towards remote training, offering companies much-needed flexibility. Many processors are also utilizing enhanced classroom training techniques, such as 3D simulation technology, which allows employees to practice cleaning and equipment handling in a realistic, yet safe, environment.
Another innovative approach is the use of “just-in-time” training modules that employees can access digitally at their convenience. Some of these resources are even available on platforms like YouTube. Traditional on-the-job training remains crucial, with new employees often shadowing experienced personnel to learn essential food safety practices.
As companies strive for continuous improvement in their training initiatives, leaders are actively seeking ways to enhance the effectiveness of their programs. The Innovation Center for US Dairy serves as a primary training resource for many organizations, with some sending up to 30 employees annually to participate in workshops. Others may prefer to send a few team members to learn about food safety at academic institutions, allowing them to return and share their knowledge with colleagues.
Stubbs emphasizes the importance of informal training sessions, which often occur in break rooms or designated areas where groups of employees can gather to learn about various topics, from OSHA regulations to facility-specific food safety practices. Wagner asserts that the combination of virtual, interactive, and practical training methods is critical for maintaining high food safety standards throughout the dairy industry.
Supporting Smaller Producers
For artisan dairy producers who may lack the resources of larger brands, the Innovation Center for US Dairy is committed to providing helpful resources that empower industry professionals to conduct self-training. One of the key resources available is a comprehensive pathogen guidance document, which details best practices for maintaining safety in dairy processing facilities.
Additionally, food safety experts actively work to gather smaller operations for group training sessions and provide on-site coaching whenever feasible. Stubbs highlights that small companies often require assistance in developing their food safety plans, including understanding what elements are necessary and how to create them.
Safeicecream.org is a notable example of a collaborative online resource hub designed to aid smaller operations. Created by IDFA, the Innovation Center for US Dairy, and the North American Ice Cream Association, this platform offers templates for food safety plans, training resources, and materials in Spanish, among other valuable tools.
Effective Training Techniques
Wagner advocates for hands-on, interactive training formats that incorporate real-life scenarios to address food safety challenges effectively. Tailoring content to align with each employee’s specific role enhances engagement and relevance, while behavior-based learning ensures that knowledge is not only comprehended but also applied in daily tasks.
Including training scenarios that allow participants to actively engage with the material reinforces key concepts. Wagner emphasizes the importance of understanding the rationale behind food safety practices, illustrating this with impactful videos that feature individuals affected by foodborne illnesses, thereby personalizing the training experience.
In-person training sessions conducted by the Innovation Center for US Dairy also adopt a practical approach, where employees receive a mix of lectures and hands-on training. Participants might be presented with hypothetical scenarios, such as identifying potential contamination sources or responding to a food safety crisis, thereby preparing them for real-world challenges.
Current Trends in Food Safety Training
Recently, there has been a growing emphasis on ensuring that certain workforce members achieve certification as Preventive Controls Qualified Individuals (PCQIs). Stubbs notes that many companies are aiming to have at least two qualified individuals on staff at every facility, highlighting the importance of having personnel who are well-versed in food safety plans.
The Food Safety Preventive Controls Alliance (FSPCA) offers training programs recognized by the FDA, with courses designed for employees responsible for preparing food safety plans. These courses typically involve a minimum of 20 contact hours and are available in various formats, including in-person, virtual, and blended learning options.
In conclusion, the dairy processing industry is evolving its approach to food safety training, embracing a blend of traditional methods and modern technology. As the industry adapts to new challenges, the focus remains on equipping employees with the knowledge and skills necessary to maintain the highest standards of food safety, ultimately ensuring the health and well-being of consumers.
